oldguy44 Posted September 26, 2017 Author Share Posted September 26, 2017 It is confusing but the parts diagram calls for 7 #2 clutch plates , one is ref.#14, one is ref. #15, and 5of them are ref.#6. In reality they are all (7) ref.#6's. There is no part nos. for #14, only #15. If you needed only one thinner #2 plate you can put it in the #14 spot, if 2 thinner ones are needed, put one in the #14 spot and one in the #15 spot. Hope that makes sense to you. We are leaving for Anthem Az. For 6 months, in 2 weeks, so will have to complete this project once we are there and settled in. Will reply back once this issue is sorted. Yes I guess I would order 1 or 2 thinner plates just to be safe. Link to comment Share on other sites More sharing options...
oldguy44 Posted September 26, 2017 Author Share Posted September 26, 2017 One more issue I ran into, the friction plate #2 shown as items #7 in in the 2015 service manual are different than the rest of the friction plates used. They have green paint on one of their tabs, while all the rest have black tabs. The two green ones are not used, only the black ones. The green ones also have thinner tabs that contact the clutch basket. When assembled, the clutch pack should have 3 red tabbed friction discs and 9 black ones. That leaves you with 1 black and 2 green ones left over. The only fiber discs in the kit are 3 red ones. The only steel disc in the kit is ref.#7 clutch plate #1. What I call the "kit" is really an assortment of Yamaha XSR900 clutch parts in their separate bags. Again I hope this gives you a little more understanding of what to do. It gets really clear after the 3rd time. Link to comment Share on other sites More sharing options...
skipperT Posted September 26, 2017 Share Posted September 26, 2017 Oldguy- couple questions: Did you install the judder spring and washer first before any clutch plates? Are they facing the correct direction? Did you install the friction plate that is thinner next? Meaning, the friction plate which is narrower then the rest, to allow for the judder spring and washer to fit neatly inside when assembled? Skip Link to comment Share on other sites More sharing options...
skipperT Posted September 26, 2017 Share Posted September 26, 2017 Regarding the above descriptions in the chart: Clutch plate 2 UR refers to the available plates that comes in 3 different thicknesses. 1.6, 2.0, or 2.3 mm. This is the plate which is switched out to bring the “stack” into specifications. Oldguy- it sounds like you were aware of setting the stack height, so I don’t think that’s your issue. BTW - Yamaha does sell an entire clutch kit for the XSR that includes ALL the plates you will need, including ones for the adjustment of the stack, a crankcase cover gasket, and the 3 springs. P/N BN0-W001G-00-00 bn(zero) That’s what I used for mine if you don’t want to reuse any of the FJ stock parts. Link to comment Share on other sites More sharing options...
oldguy44 Posted September 26, 2017 Author Share Posted September 26, 2017 Correction, 3 red and 6 black friction plates, for 9 total. Link to comment Share on other sites More sharing options...
oldguy44 Posted September 26, 2017 Author Share Posted September 26, 2017 Yes Link to comment Share on other sites More sharing options...
Buggy Nate Posted September 27, 2017 Share Posted September 27, 2017 Regarding the above descriptions in the chart: Clutch plate 2 UR refers to the available plates that comes in 3 different thicknesses. 1.6, 2.0, or 2.3 mm. This is the plate which is switched out to bring the “stack” into specifications. Oldguy- it sounds like you were aware of setting the stack height, so I don’t think that’s your issue. BTW - Yamaha does sell an entire clutch kit for the XSR that includes ALL the plates you will need, including ones for the adjustment of the stack, a crankcase cover gasket, and the 3 springs. P/N BN0-W001G-00-00 bn(zero) That’s what I used for mine if you don’t want to reuse any of the FJ stock parts. Thanks for posting this mate, it is on my list of things to do. I have already done a hydraulic conversion but more lightness and a slipper clutch will make me a happy man! Link to comment Share on other sites More sharing options...
skipperT Posted September 27, 2017 Share Posted September 27, 2017 Welcome! It’s a noticeable difference in pull, much lighter feel. Hydraulic conversion? That’s Intriguing! -Skip Link to comment Share on other sites More sharing options...
Buggy Nate Posted September 27, 2017 Share Posted September 27, 2017 Welcome! It’s a noticeable difference in pull, much lighter feel. Hydraulic conversion? That’s Intriguing! -Skip I have been meaning to do a thread for about a year now... ? I'll try to take some pics on the weekend. It was a mashup of parts from venhills kits. The handguards needed to be removed, you could make brackets to keep them though. And a very small clearance notch in the side of the switch block. Much nicer feel and no broken cables! Link to comment Share on other sites More sharing options...
Supporting Member betoney Posted September 28, 2017 Supporting Member Share Posted September 28, 2017 Oldguy- couple questions: Did you install the judder spring and washer first before any clutch plates? Are they facing the correct direction? Did you install the friction plate that is thinner next? Meaning, the friction plate which is narrower then the rest, to allow for the judder spring and washer to fit neatly inside when assembled? Skip When you get the kit, does it have installation instructions showing the specific order of the plates? or the orientation of parts? or is the installation procedure specifically from the XSR manual? ***2015 Candy Red FJ-09*** Link to comment Share on other sites More sharing options...
skipperT Posted September 28, 2017 Share Posted September 28, 2017 Bet- nope. Just a sheet of paper with what’s included and the part numbers. It also lists clutch kit part numbers for every model a kit is available for, and their contents. I used the R&R clutch section of the XSR 900 book. It took a bit to decipher how they wanted the stack to be put together, measured, and adjusted. -S Link to comment Share on other sites More sharing options...
Supporting Member betoney Posted September 28, 2017 Supporting Member Share Posted September 28, 2017 @skipperT Thanks for the info.. I have downloaded the XSR manual, I will follow that when I get around to this mod. However for today, its low 80's, I'm hitting the twisties!! ***2015 Candy Red FJ-09*** Link to comment Share on other sites More sharing options...
duhs10 Posted September 29, 2017 Share Posted September 29, 2017 Don't the '17 FJ/MT come with the slipped/assist clutch?? Why are we still going off XSR clutch diagrams? '15 FJ-09 w/ lots of extras... Fayetteville, GA, USA Link to comment Share on other sites More sharing options...
Supporting Member betoney Posted September 29, 2017 Supporting Member Share Posted September 29, 2017 Don't the '17 FJ/MT come with the slipped/assist clutch?? Why are we still going off XSR clutch diagrams?I have yet to find a 2017 parts diagram for the FJ, not sure why. Every OEM parts seller lists the '17 XSR, since its the same engine, thats the only reference I have to go by. Fortunately Part Shark sells a complete Assist/Slipper clutch kit to keep things simple. Contains: 3 x 1TD-16178-00-00 Absorber 1 x 1TD-16324-00-00 Clutch Plate 1 x 1TD-16383-00-00 Cushion Spring 1 x 1TD-16384-00-00 Seat Plate 3 x 2CR-16337-00-00 Spring Screw 3 x B90-16173-00-00 Compression Spring 3 x B90-16331-00-00 Friction Plate 1 x B90-16350-00-00 Pressure Plate Assembly 1 x B90-16352-00-00 Pressure Plate 2 1 x B90-16371-00-00 Clutch Boss 1 x 90179-20010-00 Boss Nut NOW INCLUDES: 1 x 1RC-15461-00-00 Crankcase Cover Gasket ***2015 Candy Red FJ-09*** Link to comment Share on other sites More sharing options...
duhs10 Posted September 29, 2017 Share Posted September 29, 2017 @betoney it all makes sense now hahaha I think I will do this upgrade if I ever need to replace the clutch. Or I run out of other stuff to spend money on. '15 FJ-09 w/ lots of extras... Fayetteville, GA, USA Link to comment Share on other sites More sharing options...
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